Overrunning clutch

ABSTRACT

A one-way clutch includes a first race having a plurality of pockets, each pocket defining a pivot center, a second race including a plurality of notches, a plurality of rockers, each rocker being supported on a respective pocket for pivoting movement about a pivot center relative to the second race, and a spring for urging a rocker toward engagement with a notch.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates in general to a clutch that produces a drive connection between components when their relative rotation is in one direction, and overruns when relative rotation is in the opposite direction. In particular, the invention pertains to such clutches having rockers that engage or disengage at least partially due to the effect of centrifugal force acting on the rocker.

2. Description of the Prior Art

Conventional one-way clutches for producing a one-way drive connection between inner and outer races of the clutch include sprags or rollers for releasably driveably connecting the races and the components of a mechanical assembly connected to the races. Such clutches are commonly used in the powertrain or driveline of an automotive vehicle. One-way clutches perform satisfactorily in many cases, but certain applications, such as those in which large magnitudes of torque are transmitted by the clutch or those that provide only a small space for the clutch, require one-way clutches other than conventional sprag-type or roller-type clutch to meet desire requirements.

Conventional one-way clutch assemblies have at least one sprag or roller, which driveably locks two notched or pocketed races together mutually in one rotary direction and allows the races to rotate freely in the other direction. Rocker and sprag type one-way clutch assemblies can increase the torque capacity for a given package size compared to those of a roller-type clutch, but they are generally limited in torque transmitting capacity by the magnitude of the contact or bearing stresses caused by contact of the rockers or sprags with the races.

To overcome these and other difficulties, a one-way overrunning clutch described in U.S. Pat. No. 5,070,978 includes a drive member and a driven member, which are mounted for clockwise and counterclockwise rotation about a common axis. The drive member includes a planar drive face, normal to the common axis, which connects with a source of power for rotating the planar drive face either clockwise or counterclockwise. The driven member includes a planar driven face, positioned in close proximity to and in confronting relationship with the drive face. The drive and driven members are coupled to one another through a series of pockets in one of the drive faces, and a plurality of cooperating struts carried by the other face, such that when the drive member is driven counterclockwise, it drives the driven member with it. When the drive member is driven clockwise, it does not drive the driven member, but rotates freely relative to the driven member. Column stability of the strut, which transmits the torsional load between the races, is an important factor in the design.

U.S. Pat. No. 5,954,174 discloses a ratchet one-way clutch assembly having an inner race with notches, an outer race with pockets, and rockers located in the pockets to engage the notches. The rockers have a pivot ridge which mates with a peak or recess in the pockets in the outer race to position the rocker in the pocket. The center of mass of each rocker is located such that the rocker tends to engage or disengage a notch in the inner race. A spring is used to provide a tilting force on each rocker directed to produce engagement of the rocker with a notch.

Conventional one-way clutches develop relatively large magnitudes of hoop stress in the races when torque is transmitted through the clutch; therefore, the races of conventional one-way clutches are formed of bearing grade steel in order to withstand the operating hoop stress. Because the clutches disclosed in the '978 and '245 patents develop relative low operating hoop stresses in service, those clutches can be formed of powered metal. Clutches formed for powered metal potentially can be produced at relative low cost compared to the cost to form and produce a conventional clutch of high grade steel, provided extensive machining is avoided.

The clutches described in the '978 or '245 patents, however, require a significant amount of machining of the components that are formed of powered metal. Excessive internal backlash, which can produce noise at unacceptable levels, is potentially a problem under certain operating conditions with these clutches.

A need exits, therefore, for a low cost, reliable one-way clutch that produces low operating bearing stresses and is able to be formed readily from powered metal. The clutch should occupy little space, minimize in-service noise, and require little or no machining. Preferably the desired clutch should include features that facilitate its assembly in a drive system.

SUMMARY OF THE INVENTION

The present invention provides a one-way clutch having an inner race, outer race, and pivoting rockers that driveably connect the races in one rotary direction and overrun in the opposite direction. The clutch is preferably formed of powered metal. The rockers are located in one of the races, such that the clutch can employ centrifugal force to assist in disengaging the rockers from a notch plate during an overrun condition by biasing the rockers to pivot away from the notch plate. Alternately, the clutch can employ centrifugal force to assist in engaging the rockers with a notch plate by urging the rockers to pivot toward notch plate.

The shape of a pocket plate, which contains the rockers, uniquely requires no secondary machining operations for any purpose, such as to eliminate densifiers and de-densifiers in the powered metal components. The components of the clutch that are formed from powered metal require no machining after they are formed.

The number of notches for a given diameter is greater than other one-way clutches, thereby significantly reducing backlash. The design lends itself to easy assembly due to its configuration. A pocket plate subassembly contains the rockers and a return spring for each rocker. Before its assembly in the clutch, the pocket plate subassembly restricts the ability of each rocker to pivot in the pocket, and the force of the respective return spring prevents the rocker from exiting the pocket laterally by forcing the rocker into contact with its pocket. This arrangement permits the subassembly to be handled and transported prior to its installation in the clutch with the rockers and springs already installed in the pocket plate subassembly.

An overrunning one-way clutch according to this invention includes a first race having a plurality of pockets, each pocket defining a pivot center, a second race including a plurality of notches, a plurality of rockers, each rocker being supported on a respective pocket for pivoting movement about a pivot center relative to the second race, and a spring for urging a rocker toward engagement with a notch.

Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a clutch according to the present invention showing rockers located in an inner race and engaged with notches in an outer race;

FIG. 2 is an isometric view of the clutch assembly showing the components mutually spaced axially;

FIG. 3 is a isometric view of the clutch assembly of FIG. 2 partially in cross section taken at a diametrical plane showing the components in spaced relationship;

FIG. 4 is an isometric view of the clutch assembly of FIG. 2 partially in cross section through a diametrical plane showing the components assembled;

FIG. 5 is a side view, partial cross section through a diametrical plane showing the components assembled;

FIG. 6 is a side view of a portion of an inner race showing a rocker, pocket and return spring;

FIG. 7 is a side view of a portion of an inner race showing a rocker, pocket, return spring, and a CF vector;

FIG. 8 is a side view of a clutch showing rockers located in an outer race and engaged with notches in an inner race;

FIG. 9 is a side view of a portion of an outer race showing a rocker, pocket, return spring, and a CF vector;

FIG. 10 is a side view of an accordion return spring; and

FIG. 11 is a side view of a helical return spring.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, there is illustrated in FIG. 1 a one-way clutch assembly 20 in accordance with the present invention. The clutch assembly 20 includes an inner race or rocker plate 22, an outer race or cam plate 24, and a plurality of rockers 26, each rocker being located in a pocket 28 formed in the inner race 22 and angularly spaced mutually about a central axis 30. The inner periphery of the outer race 24 is formed with a plurality of cams or notches 32 angularly spaced mutually about axis 30. There are twelve rockers 26 and pockets 28 and thirty-six notches 32 in the clutch illustrated in FIG. 1.

When the inner race 22 rotates clockwise faster than the outer race 24, each rocker 26 pivots counterclockwise in its pocket 28 away from engagement with the notches 32 due to contact of the rockers with the inner radial surface of the outer race. This allows the inner race 22 freely to rotate clockwise about axis 30 relative to the outer race 24. When the inner race 22 attempts to rotate counterclockwise relative to the outer race 24, the inner race and outer race are engaged or driveably connected mutually by engagement of the rockers 26 with the notches 32.

When the clutch 20 is engaged, each engaged rocker 26 transmits a force F between the inner and outer races 22, 24 due to its contact with the inner surface 34 of the pocket and with the radially directed surface 36 of the engaged notch 32.

A recesses 40, located at each pocket 28, contains a spring, such as a helical coiled compression spring 42 or an accordion compression spring 44, for urging each rocker to pivot in its pocket toward engagement with the notches.

FIG. 2-5 show a clutch having a rocker plate 22 formed with angularly spaced pockets 28 and spring recesses 40, each pocket containing a rocker 26 that pivots in a respective pocket alternately to engage and to disengage the notches 32 formed on the radially inner surface of the cam plate 24. A bushing 46 of powered metal fits within the cam plate 24.

As seen best in FIG. 5, when clutch 20 is assembled, an axial surface of bushing 46 contacts an inner axial surface 48 of a flange 50. Surface 48 is formed with radially directed grooves 52, which carry fluid lubricant, preferably transmission oil, radially outward a radial inner surface of the bushing 46. Oil enters the radial grooves 52 through holes 49 formed through a drive system component 72 that are connected to the clutch 20. The oil travels axially leftward across the inner radial surface 51 on the bushing 46, to a radial space 53, which directs the oil radially outward to surface 55, across the width of the rocker plate 22 and across the surface of the rockers 26. Bushing 46 pilots the inner and outer races 22, 24 and eliminates need to machine along the notches or cams 32 of the outer race or the radial outer surface area 66 of the rocker plate 22. Lubricating oil is precisely directed radially along grooves 52 to the bushing 46, then axially between surfaces 68 on the rocker plate 22 and the inside diameter 51 of the bushing to the rockers 26. The lubricant flows along this path due to a centrifugal pressure head developed as the clutch rotates about axis 30.

The radial outer surface of the cam plate 24 is formed with spline 54, by which the cam plate is driveably connected to a drive system. Similarly, the radially inner surface of the rocker plate 24 is formed with spline 56, by which the rocker plate is driveably connected to a component of the drive system.

An axial surface 58 of rocker plate 22 contacts a retainer ring 60, which closes the axial end of each pocket 28 and is retained in position by a snap ring 62, which engages a recess 64 formed on the cam plate 24.

FIGS. 3 and 4 show the components of the clutch 20 located immediately adjacent their assembled positions and in the assembled positions, respectively. The clutch 20 is assembled with the cam plate 24 driveably connected by spline 70 to a drum 72 of a vehicle drive system.

Referring now to FIG. 6, a preferred embodiment of rocker 26 may include several surfaces 80, 82, 84, 86, 88 and a defined pivot center 90. Surfaces 80 and 82 are both circular cylindrical surfaces whose arcs are concentric with the pivot center 90. Surfaces 80, 82 guide rotation or pivoting of the rocker 26 and limit that pivoting to one degree of freedom. The arcs of both surfaces 80, 82 must be sufficient such that the neck or strut portion 92 of the rocker is narrower than the counterweight portion 94 in order to restrain the rocker in the radial direction from center 90.

Surface 80 is a guiding surface. When force F is applied while the clutch is driving and a rocker 26 is engaged with a notch 32, preferably no reaction force is developed on surface 80. Surface 82 is a surface on which the reaction to force F is developed when clutch 20 is transmitting torque between the outer race and inner race 22 through the rocker 26. Because the center of surface 82 is located at the pivot center 90, the reaction to force F is distributed along surface 82 and produces no torque tending to pivot the rocker 26 about the pivot center.

Surface 84 limits clockwise pivoting of the rocker 26 and assists assembly of the race 22, 24 that contains the pocket 28, rocker 26 and the springs. That race is prepared for installation by inserting a rocker 26 in each pocket and placing a spring 42, 44 in each recess 40. The force applied by the spring on its respective rocker rotates the rocker to the position shown in FIG. 6 where surface 84 contacts the base 96 of the pocket 28. The spring force and its reaction force on the base 96 retains the rocker in the pocket without the presence of the other race or another assembly aid. The race containing the rockers can be transported readily with the rockers in this retained condition preparatory to installing the race subassembly in the clutch assembly 20.

By limiting pivotal rotation of the rocker 26 about pivot center 90, a counter-rotation reaction force on the strut is generated at surface 84 when the clutch is driving or engaged. When clutch 20 is driving, force F, applied to rocker surface 86, produces a clockwise torque on the rocker about the pivot center 90. Torque about center 90 produced by force F is reacted by a force P1 where rocker surface 84 contacts pocket surface 96. Without surface 84, the full reaction torque would be reacted elsewhere. For example, if the full torsion reaction to force F were applied to rocker surface 88, a large hoop stress would be generated on the race contacted by surface 88 tending to shear the wall of that race due to a high angle of incidence of the reaction force. If the torsion reaction to force F were applied to surface 82, it would be applied at the extremity of the inner race at its weakest point. Preferably, the torsion reaction to force F is located normal to the pocket base 96 at rocker surface 84, and on surface 82 where friction is developed due to contact with the pocket.

Surface 86 is the surface on which force F is applied when the clutch 20 is driving and the rockers 26 are engaged with the radial surfaces 36 of the notches 32. Surface 86 performs this function by creating a mechanical interference when the rocker is pivoted to the engaged position.

Surface 88, located at the contour of the strut portion 92 of the rocker 26, contacts the crest 98 of the radial surfaces 36 of the notches 32 to ensure no interference when the clutch 20 is overrunning and the rockers 26 are disengaged from the notches 32. Surface 88 is curved to facilitate formation of a film of lubricant while the clutch is overrunning. Surface 88 is curved also to minimize impact with the crests 98 while the clutch overruns by providing transitional positions that minimize the rate of rotation of the rocker into the pocket relative to the rate of rotation of the outer race. This minimizes angular acceleration on the rocker as the clutch overruns.

The center of mass 100 of the rocker 26 can be located in relation to the pivot center 90 such that centrifugal force tends either to engage or to disengage the rocker, whether the rocker is located on the outer race or the inner race.

When viewed as in FIG. 7, the center of mass 100 is located rightward from a line connecting the axis 30 and the pivot center 90, and the rocker is carried in a pocket located on an inner race 22. As the clutch assembly 20 rotates about axis 30, centrifugal force on the rocker is directed radially outward along a line 102 that passes through axis 30 and the center of mass 100, causing the rocker 26 to pivot counterclockwise about the pivot center 90. This counterclockwise pivoting of the rocker opposes the force of the spring and tends to pivot rocker surface 86 away from contact with pocket surface 36 on the inner race 24. This counterclockwise pivoting of the rocker tends to move the rocker to a disengaged position, and allows the inner race 22 to overrun and the clutch 20 to disengage. The magnitude of the moment about pivot center 100 tending to compress spring 42 and to pivot the rocker 26 to the disengaged position varies with the speed of rotation of the inner race and the distance of the center of mass 100 from the pivot center 90.

Alternatively, the center of mass may be located leftward from a line connecting the axis 30 and the pivot center 90, when the rocker is carried in a pocket located on an inner race 22. In that case, as the clutch assembly 20 rotates about axis 30, centrifugal force on the rocker causes the rocker 26 to pivot clockwise about the pivot center 90. This clockwise pivoting of the rocker adds to the effect of the force of spring 42, tends to move surface 86 of the rocker toward contact with radial surface 36 on the outer race 24, i.e., to pivot the rocker 26 to an engaged position, and causes the clutch to engage.

FIG. 8 illustrates an embodiment of a clutch assembly 120, in accordance with the present invention. The clutch assembly 120 includes an inner race or rocker plate 122, an outer race or cam plate 124, and a plurality of rockers 126, each rocker being located in a pocket 128 formed in the outer race 124 and angularly spaced mutually about a central axis 130. The outer periphery of the inner race 122 is formed with a plurality of cams or notches 132, angularly spaced mutually about axis 30. There are nine rockers 126 and pockets 128 and thirty-six notches 132 in the clutch illustrated in FIG. 1.

When the outer race 124 rotates clockwise faster than the inner race 122, each rocker 126 pivots clockwise in its pocket 128 away from engagement with the notches 132 due to contact of the rockers with the outer radial surface of the inner race. This allows the outer race 124 freely to rotate clockwise about axis 130 relative to the inner race 122. When the outer race 124 attempts to rotate counterclockwise relative to the inner race 122, the inner race and outer race are engaged or driveably connected mutually by engagement of the rockers 126 with the notches 132.

When the clutch 120 is engaged, the engaged rockers 126 each transmit a force between the inner race 122 and outer race 124 due to the rocker's contact with the inner surface 134 of the pocket 128 and with the radially directed surface 136 of the engaged notch 132.

A recess 140, located at each pocket 28, contains a spring, such as a helical coiled compression spring 142 or an accordion compression spring 144, for urging each rocker to pivot in its pocket toward engagement with the notches.

When the clutch assembly 120 is viewed as in FIG. 9, the center of mass 150 of each rocker 126 is located rightward from a line connecting the axis 130 and the pivot center 152. As the outer race 124 rotates about axis 130, centrifugal force on the rocker is directed radially outward along a line 154 that passes through axis 130 and the center of mass 150, causing the rocker 126 to pivot counterclockwise about the pivot center 152. This counterclockwise pivoting of the rocker cooperates with the force of the spring tending to pivot the rocker to an engaged position with surface 136, and to engage the clutch.

Alternatively in the clutch assembly 120, the center of mass 150 of each rocker 126 may be located leftward from a line connecting the axis 130 and the pivot center 152. In that case, as the outer race 124 rotates about axis 30, centrifugal force on the rocker 126 causes the rocker to pivot clockwise about the pivot center 152. This clockwise pivoting of the rocker opposes the effect of the spring force and tends to pivot surface 86 of the rocker away from contact with radial surface 136 on the inner race 122. This action tends to move the rocker to a disengaged position and allows the clutch to overrun and to disengage.

In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.

In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope. 

1. A one-way clutch comprising: a first race having a plurality of pockets, each pocket including an interior cylindrical surface on a wall of the pocket, said surface having a pivot center that is located at a first center of said cylindrical surface; a second race including a plurality of notches; a plurality of rockers, each rocker being supported on a respective pocket for pivoting movement about the pivot center relative to the second race, each rocker including first and second exterior partial cylindrical surfaces having a second center, said first surface being spaced a first radial distance from the second center, said second surface being spaced a second radial distance from the second center, the first and second distances being mutually unequal, an axis through the pivot center passing through the first center and the second center when the rocker pivots toward engagement with the second race; and a multiple springs, each spring urging a respective rocker toward engagement with a notch.
 2. The clutch of claim 1, wherein each rocker includes a center of mass positioned relative to said pivot center such that, upon rotation of the first race, each rockers is biased by centrifugal force toward engagement with the notch.
 3. The clutch of claim 1, wherein each rocker includes a center of mass positioned relative to said pivot center such that, upon rotation of the first race, each rockers is biased by centrifugal force away from engagement with a notch.
 4. The clutch of claim 1 wherein the spring is one of an accordion compression spring and a helical compression spring.
 5. The clutch of claim 1 wherein said first distance is less than the second distance, and the second surface is complementary to said surface on the wall of the respective pocket.
 6. The clutch of claim 1 wherein: the first race further includes a recess spaced from the pivot center of a respective pocket, directed toward a rocker located in the respective pocket, and containing one of said springs; and the pocket includes a limit surface, for contacting the rocker and limiting pivotal movement of the rocker about the pivot center due to a force produced by the spring.
 7. The clutch of claim 1 wherein: the first race further includes a recess spaced from the pivot center, directed toward the rocker, and containing the spring; the spring contacts the rocker urging the rocker to pivot about the pivot center toward the outer second race; and the pocket includes a limit surface, for contacting the rocker and limiting pivotal movement of the rocker about the pivot center due to a force produced by the spring.
 8. The clutch of claim 7, wherein the spring urges the rocker to pivot about the pivot center into contact with the limit surface, whereby the rocker is retained in the pocket due to the effects of the force of the spring and contact between the limit surface and the rocker.
 9. The clutch of claim 1, further comprising a bushing located in a space between the outer race and the inner race, including a pilot surface for guiding the inner race into an assembled position relative to the outer race.
 10. A one-way clutch comprising: an inner race having a plurality of pockets spaced angularly about an axis, each pocket defining a pivot center that is located at a first center of an interior circular cylindrical surface on a wall of the pocket; an outer race including a plurality of notches spaced angularly about the axis and facing the pockets; a plurality of rockers, each rocker being supported on a respective pocket for pivoting movement about the pivot center relative to a notch, each rocker including first and second exterior partial cylindrical surfaces having a second center, said first surface being spaced a first radial distance from the second center, said second surface being spaced a second radial distance from the second center, the first and second distances being mutually unequal, an axis through the pivot center passing through the first center and the second center when the rocker pivots toward engagement with the second race; and springs located on the inner race, each spring urging a rocker radially outward toward engagement with a notch.
 11. The clutch of claim 10, wherein each rocker includes a center of mass positioned relative to a respective pivot center such that, upon rotation of the inner race, the respective rocker is biased by centrifugal force toward engagement with the notches.
 12. The clutch of claim 10, wherein each rocker includes a center of mass positioned relative to said pivot center such that, upon rotation of the inner race, the respective rocker is biased by centrifugal force away from engagement with the notches.
 13. The clutch of claim 10 wherein each spring is one of an accordion compression spring and a helical compression spring.
 14. The clutch of claim 10 wherein said first distance is less than the second distance, and the second surface is complementary to said surface on the wall of the respective pocket.
 15. The clutch of claim 10 wherein: the inner race further includes recess, each recess spaced from the pivot center of a respective pocket, directed toward a respective rocker located in the respective pocket, and containing one of said springs; and each pocket includes a limit surface, for contacting the respective rocker and limiting pivotal movement of said rocker about said pivot center due to a force produced by the spring.
 16. The clutch of claim 10 wherein: the inner race further includes recesses, each recess spaced from a respective pivot center, directed toward a respective the rocker, and containing the spring; the spring contacts the respective rocker urging said rocker to pivot about the respective pivot center toward the outer race; and each pocket includes a limit surface, for contacting the respective rocker and limiting pivotal movement of said rocker about the respective pivot center due to a force produced by the spring.
 17. The clutch of claim 16, wherein the spring urges said rocker to pivot about said pivot center into contact with said limit surface, whereby said rocker is retained in said pocket due to the effects of the force of said spring and contact between the limit surface and the rocker.
 18. A one-way clutch comprising: an outer race having a plurality of pockets spaced angularly about an axis, each pocket defining a pivot center that is located at a first center of an interior circular cylindrical surface on a wall of the pocket; an inner race including a plurality of notches spaced angularly about the axis and facing the pockets; a plurality of rockers, each rocker being supported in a respective pocket for pivoting movement about the pivot center relative to a notch, each rocker including first and second exterior partial cylindrical surfaces having a second center, said first surface being spaced a first radial distance from the second center, said second surface being spaced a second radial distance from the second center, the first and second distances being mutually unequal, an axis through the pivot center passing through the first center and the second center when the rocker pivots toward engagement with the second race; and springs located on the outer race, each spring urging a rocker radially inward toward engagement with a notch.
 19. The clutch of claim 18, wherein each rocker includes a center of mass positioned relative to a respective pivot center such that, upon rotation of the outer race, the respective rocker is biased by centrifugal force toward engagement with the notches.
 20. The clutch of claim 18, wherein each rocker includes a center of mass positioned relative to said pivot center such that, upon rotation of the outer race, the respective rocker is biased by centrifugal force away from engagement with the notches.
 21. The clutch of claim 18 wherein each spring is one of an accordion compression spring and a helical compression spring.
 22. The clutch of claim 18 wherein said first distance is less than the second distance, and the second surface is complementary to said surface on the wall of the respective pocket.
 23. The clutch of claim 18 wherein: the outer race further includes recess, each recess spaced from the pivot center of a respective pocket, directed toward a respective rocker located in the respective pocket, and containing one of said springs; and each pocket includes a limit surface, for contacting the respective rocker and limiting pivotal movement of said rocker about said pivot center due to a force produced by the spring.
 24. The clutch of claim 18 wherein: the outer race further includes recesses, each recess spaced from a respective pivot center, directed toward a respective the rocker, and containing the spring; the spring contacts the respective rocker urging said rocker to pivot about the respective pivot center toward the outer race; and each pocket includes a limit surface, for contacting the respective rocker and limiting pivotal movement of said rocker about the respective pivot center due to a force produced by the spring.
 25. The clutch of claim 24, wherein the spring urges said rocker to pivot about said pivot center into contact with said limit surface, whereby said rocker is retained in said pocket due to the effects of the force of said spring and contact between the limit surface and the rocker. 